Vehicle system for controlling motor torque

Abstract

A vehicle having a vehicle system is provided with a motor having a housing and a stator. The motor is configured to provide motor torque for vehicle propulsion. The vehicle system is also provided with at least one controller that is configured to receive input indicative of at least one of the housing temperature and the stator temperature, and control the motor torque based on a comparison of the input to predetermined thermal data.

1. A vehicle system comprising:
 a motor having a housing and a stator, and configured to provide motor torque for vehicle propulsion; and 
 at least one controller configured to receive input indicative of at least one of the housing temperature and the stator temperature, and control the motor torque based on a comparison of the input to predetermined thermal data, wherein the predetermined thermal data includes a predetermined high temperature indicative of a motor temperature above which the housing expands and disengages from the stator when the motor is operating at maximum motor torque; 
 wherein the at least one controller is further configured to compare at least one of the housing temperature and the stator temperature to the predetermined high temperature to evaluate motor performance. 
 
     
     
       2. The vehicle system of  claim 1  wherein the housing defines an inner bore, and the stator is formed in a generally cylindrical shape with an outer surface adapted to engage the inner bore for securing the stator to the housing; and
 wherein the predetermined thermal data is indicative of a temperature condition for maintaining engagement between the housing and the stator. 
 
     
     
       3. The vehicle system of  claim 1  wherein the at least one controller comprises a vehicle controller communicating with at least one sensor coupled to the motor, the vehicle controller configured to:
 receive the input indicative of at least one of a housing temperature and a stator temperature from the at least one sensor; 
 compare at least one of the housing temperature and the stator temperature to the predetermined thermal data to evaluate motor performance; and 
 provide output indicative of a motor torque request in response to the motor performance. 
 
     
     
       4. The vehicle system of  claim 3  wherein the at least one controller further comprises a control module communicating with the motor and the vehicle controller, wherein the control module is configured to control the motor torque based on the output of the vehicle controller, by providing current to the motor that corresponds to the motor torque request. 
     
     
       5. The vehicle system of  claim 1  wherein the predetermined thermal data further comprises a predetermined temperature difference indicative of a minimum value for maintaining engagement between the stator and the housing when the motor is operating at maximum motor torque; and
 wherein the at least one controller is further configured to:
 calculate a temperature difference value based on a difference between the stator temperature and the housing temperature, and 
 compare the temperature difference value to the predetermined temperature difference to evaluate motor performance. 
 
 
     
     
       6. The vehicle system of  claim 5  wherein the predetermined thermal data further comprises a predetermined motor torque limit that is less than a maximum motor torque, and wherein the at least one controller is further configured to:
 receive a throttle request that corresponds to a desired motor torque; 
 compare the throttle request to the predetermined motor torque limit; and 
 provide the motor torque request based on the predetermined motor torque limit when the desired motor torque exceeds the predetermined motor torque limit, the housing temperature and the stator temperature exceed the predetermined high temperature, and the temperature difference value is less than the predetermined temperature difference. 
 
     
     
       7. A vehicle system comprising:
 at least one controller configured to:
 receive input indicative of a motor housing temperature and a motor stator temperature, 
 calculate a temperature difference value based on a difference between the housing temperature and the stator temperature, 
 compare the temperature difference value to a predetermined temperature difference to evaluate motor performance, and 
 provide output indicative of a motor torque request in response to the motor performance. 
 
 
     
     
       8. The vehicle system of  claim 7  wherein the at least one controller is further configured to control motor torque based on the output. 
     
     
       9. The vehicle system of  claim 7  further comprising:
 a housing sensor connected to a motor coolant line extending from the housing, and configured to provide a housing signal indicative of the motor housing temperature to the at least one controller; and 
 a stator sensor connected to a motor winding extending from the stator, and configured to provide a stator signal indicative of the stator temperature to the at least one controller. 
 
     
     
       10. The vehicle system of  claim 7  wherein the at least one controller is further configured to provide output indicative of a motor torque request that is less than a maximum motor torque when the temperature difference value is less than the predetermined temperature difference. 
     
     
       11. The vehicle system of  claim 7  wherein the at least one controller is further configured to compare at least one of the housing temperature and the stator temperature to a predetermined high temperature to evaluate motor performance, wherein the predetermined high temperature is indicative of a temperature of a motor, above which the motor housing expands and disengages from the motor stator, when the motor is operating at full motor torque. 
     
     
       12. The vehicle system of  claim 11  wherein the predetermined high temperature is between 55 and 65 degrees Celsius. 
     
     
       13. The vehicle system of  claim 11  wherein the at least one controller is further configured to limit motor torque by providing a motor torque request that is less than a maximum motor torque when the temperature difference value is less than the predetermined temperature difference and each of the motor stator temperature and the motor housing temperature are above the predetermined high temperature. 
     
     
       14. A vehicle comprising:
 a motor having a housing and a stator and configured to provide torque for vehicle propulsion; 
 at least one sensor coupled to the motor and configured to provide a signal indicative of at least one of a housing temperature and a stator temperature; 
 at least one controller communicating with the motor and configured to control the motor torque based on a comparison of the signal to predetermined thermal data; and 
 a user interface in communication with the controller and configured to display a motor status message based on the comparison of the signal to the predetermined thermal data. 
 
     
     
       15. The vehicle of  claim 14  wherein the at least one controller further comprises:
 a control module communicating with the motor; and 
 a controller communicating with the control module and the at least one sensor, the controller configured to:
 compare at least one of the housing temperature and the stator temperature to the predetermined thermal data to evaluate motor performance, and 
 provide output to the control module indicative of a motor torque request in response to the motor performance; 
 
 wherein the control module is configured to control the motor torque based on the output of the controller. 
 
     
     
       16. The vehicle of  claim 14  further comprising:
 a coolant system having at least one coolant line connected to the housing for circulating a fluid through the housing; 
 wherein the at least one sensor comprises a housing sensor connected to the coolant line and configured to provide the signal indicative of the housing temperature. 
 
     
     
       17. The vehicle of  claim 14  further comprising:
 a battery electrically connected to at least one winding extending through the stator for providing electrical current to the motor; 
 wherein the at least one sensor comprises a stator sensor connected to the at least one winding and configured to provide the signal indicative of the stator temperature. 
 
     
     
       18. The vehicle of  claim 17  wherein the at least one controller is further configured to compare at least one of the housing temperature and the stator temperature to a predetermined high temperature to evaluate motor performance;
 wherein the predetermined high temperature is indicative of a motor temperature above which the housing expands and disengages from the stator when the motor is operating at full motor torque. 
 
     
     
       19. A vehicle system comprising:
 a motor having a housing and a stator, and configured to provide motor torque for vehicle propulsion; and 
 at least one controller configured to receive input indicative of the housing temperature and the stator temperature, and to limit the motor torque based on a difference between the stator temperature and the housing temperature.